101605-0220 ZEXEL 9 400 612 786 BOSCH INJECTION-PUMP ASSEMBLY 9400612786 1016050220 1156034600

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 786 9400612786

ZEXEL 101605-0220 1016050220

ISUZU 1156034600 1156034600

Service parts 101605-0220 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8540

3. GOVERNOR 105419-4930

4. SUPPLY PUMP 105220-7580

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-4520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8280

11. Nozzle and Holder 1-15300-425-0

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/22.1{225}

13. NOZZLE-HOLDER 105041-4410

14. NOZZLE

15. NOZZLE SET 105019-2820

Include in #1:

101605-0220 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-1051 as _

Cross reference number

BOSCH 9 400 612 786 9400612786

ZEXEL 101605-0220 1016050220

ISUZU 1156034600 1156034600

Zexel num

Bosch num

Firm num

Name

101605-0220

9 400 612 786

1156034600 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 K 14BF INJECTION PUMP ASSY PE6AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-4920

Overflow valve opening pressure kPa 127 127 127

Overflow valve opening pressure kgf/cm2 1.3 1.3 1.3

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4 3.95 4.05

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 53 51.5 54.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 10.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 140 150

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle (1)Speed set at aa (setting at supply) (2)Stopper bolt setting (3)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=19deg+-5deg b=7deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=4.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(100deg)